Containers and Materials With Improved Punctureability

ABSTRACT

The present description includes containers having an improved puncture design that can be punctured without substantial deformation of the container. Such containers are particularly suitable for use in preparing beverages using automatic machines, particularly those used for preparation of single serve beverages. Also provided are thermoplastic materials having improved punctureability for use in containers, containers for preparation of a beverage, and methods for preparing a beverage using such containers.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority under 35 U.S.C. §119(e) to U.S.Provisional Application No. 61/811,397 filed on Apr. 12, 2013, thedisclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

The present application relates generally to the field of containers forpreparation of beverages, especially coffee and tea. These containerscommonly are referred to as cartridges, cups, capsules, or pods, and areparticularly suitable for use in the preparation of a single-servebeverage.

In recent years, single-serve beverage machines have become popular inhomes and businesses as a quick and convenient manner of brewingbeverages. These machines generally brew coffee, tea, or other hotbeverages through polymer containers that may have integral filters andare filled with coffee grinds, tea leaves, or other soluble products.Upon brewing of these products, the container may be easily discarded sothat the machine is available for preparation of subsequent beverages.These containers thereby enable users to customize their beverages andalso enjoy freshly brewed beverages quickly and easily.

Although convenient, existing containers used for the preparation ofbeverages have numerous drawbacks. For example, many commerciallyavailable containers are prepared using materials that are less easilyrecycled. This is due at least in part due to the structuralcharacteristics that are required for these containers. For example, thecontainers must be sufficiently strong to permit puncturing of the baseof the container without substantial deformation of the container. Thus,there exists a need for a structure that permits use of more easilyrecycled materials while still having sufficient structural integrity.

SUMMARY OF THE DESCRIPTION

Embodiments of the present description address the above-described needsby providing a container including a substantially circular base; afrustoconically shaped wall extending therefrom and defining a cavitytherein; and a stacking shoulder which intersects and extends laterallyfrom the wall. The base includes an annular support structure with acontinuous puncture region therein, the continuous puncture region beingsized and shaped to permit a puncture therein without interference andwithout substantial deformation of the container. The annular supportstructure desirably is positioned an effective distance from the edge ofthe base to increase the punctureability of the base in the continuouspuncture region.

Also provided in embodiments herein are containers for preparation of abeverage using the above-described container and methods for preparing abeverage using such containers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an embodiment of a container according to afirst embodiment.

FIG. 2 is a bottom view the container illustrated in FIG. 1.

FIG. 3 is a top view of the container illustrated in FIG. 1.

FIG. 4 is a forward lower perspective view of the container illustratedin FIG. 1.

FIG. 5A and FIG. 5B are schematic illustrations of a design that may beapplied to the inner surface of a cup base according to embodiments.

FIG. 6 is a cross-sectional side view of an embodiment of the containerillustrated in FIG. 1.

DETAILED DESCRIPTION

Embodiments of the present application address the above-described needsby providing a container for preparation of a beverage. As used herein,the term “container” is synonymous with cartridges, cups, capsules,pods, and the like, that may be used in the preparation of a beverage.

The container generally comprises a cup-shaped container with a base anda frustoconically shaped sidewall defining an opening. In an embodiment,the base includes an annular support structure. A continuous punctureregion disposed within the annular support structure is configured topermit the container base to be punctured in the continuous punctureregion during the preparation of the beverage. The annular supportstructure desirably is positioned an effective distance from the edge ofthe base to increase the punctureability of the base in the continuouspuncture region.

An exemplary embodiment of a container 10 is further illustrated inFIGS. 1-4. The container 10 comprises the base 12 and thefrustoconically shaped sidewall 14 defining an opening 16. The sidewall14 may include a radially outwardly protruding lip 18 surrounding theopening 16. In one aspect, the radially outwardly protruding lip 18further comprises a stacking shoulder 19 that intersects and extendslaterally from the sidewall 14.

The base 12 includes an annular support structure 20 with a continuouspuncture region 22 therein. The annular support structure 20 desirablyis positioned an effective distance away from the edge 24 of the base12.

The continuous puncture region disposed inside the annular supportstructure 20 is configured to permit the puncture of the container baseat any position in the continuous puncture region 22 during preparationof the beverage. Although the presently described embodiment of annularsupport structure 20 is an annular shape, other shapes also may be used(e.g., elliptical, triangular, square, hexagonal, heptagonal, octagonal,and the like), provided the structure does not interfere with puncturingof the base in the continuous puncture region 22 and is positioned aneffective distance from the edge 24 of the base. Those skilled in theart will appreciate, however, that the annular shaped support structureis particularly suitable for defining a continuous puncture region thatmay be punctured at any position, thereby allowing the container to bepositioned within the beverage machine without regard for the positionof the puncture region.

In embodiments, the annular support structure may comprise more than oneannular shape. For example, the annular support structure may comprise afirst annular shape and a second annular shape positioned inside thefirst annular shape and outside the continuous puncture region. Inembodiments, the first annular support structure and the second annularsupport structure have substantially the same dimensions (i.e., widthand height). Those skilled in the art will appreciate, however, that thedimensions of the first annular support structure and second annularsupport structure may be different (i.e., different widths and thelike).

Not wishing to be bound by any theory, the position of the annularsupport structure an effective distance from the edge of the basechanges the mode of failure of the container and increases the rigidityof the base, thereby improving the punctureability of the base in thecontinuous puncture region. In exemplary embodiments, an effectivedistance from the edge of the base is from about 1 to about 10 mm, fromabout 1 to about 5 mm, from about 1.5 to about 2.5 mm, or from about 2.0to about 2.5 mm. For example, in an embodiment the annular supportstructure may be positioned about 2.3 mm from the edge of the base.

In embodiments, the container further comprises an inner supportstructure on the base disposed in the center of the continuous punctureregion, such that the continuous puncture region is positioned betweenthe annular support structure and the inner support structure (FIG. 6).The inner support structure may be annular in shape similar to theannular support structure, although other shapes also may be used (e.g.,circular, elliptical, triangular, square, hexagonal, heptagonal,octagonal, and the like), provided the shape of the inner supportstructure does not interfere with the ability to puncture the base inthe continuous puncture region.

In embodiments, the container further comprises other features tofacilitate the punctureability of the base in the continuous punctureregion. For example, in an embodiment the container may include afeature in the inner surface of the base of the container. The featuremay be effective to weaken the material of the base in the continuouspuncture region during its puncture without sacrificing its strength,for example, by providing stress concentrators. Two exemplaryembodiments of the feature are illustrated in FIGS. 5A and 5B, whichillustrate the designs that may be imprinted in the inner surface of thebase of the container. Other designs also may be used.

In an embodiment (FIG. 6), the container may be further characterized bythe following mathematical relationship:

h=(R ₁ −R)·tan(90−Φ)

wherein h is the height of the container from the base 12 to thestacking shoulder 19, R₁ is the inner radius of the container at thestacking shoulder 19, R is the radius of the base 12 at the edge 24 ofthe base, and (Φ) is the approach angle.

The container also can further be characterized by the dimensions of thebase features (FIG. 2 and FIG. 6): r₁ is the radius of the base 12 tothe outer portion of the annular support structure 20, r₂ is the radiusof the base 12 to the inner portion of the annular support structure 20,d_(o) is the effective distance from the edge 24 of the base to theannular support structure 20, w_(o) is the width of the annular supportstructure 20, w_(i) is the width of the continuous puncture region 22 ofthe base 12, and t is the height of the annular support structure 20.Accordingly, in certain embodiments the base 12 is further characterizedby the following mathematical relationships:

d _(o) =R−r ₁>0.01

w _(o) =r ₁ −r ₂>0.01

R>r₁>r₂

w _(i)=2·r ₂

In embodiments, r₁ and r₂, independent from one another, may be fromabout 0.1 to about 10.0 mm. For example, in embodiments R may be 18.8mm, r₁ may be 9.4 mm, and r₂ may be 8.25 mm, such that d_(o) is 9.4 mm,w_(o) is and 1.15 mm, w_(i) is 16.5 mm, and t is 0.65 mm. Exemplaryranges of the foregoing variables are summarized in the table below.

Dimension Exemplary Ranges height of the container h 20.0 mm-100.0 mminner radius of the R₁ 11.0 mm-55.0 mm  container at the stackingshoulder radius of the base R 10.0 mm-50.0 mm  approach angle Φ 2degrees-10 degrees effective distance from d_(o) 0.5 mm-10.0 mm edge ofbase to annular support structure outer radius of annular r₁ 4.5 mm-49.5mm support structure inner radius of annular r₂ 4.0 mm-24.5 mm supportstructure width of annular support w_(o) 0.5 mm-25.0 mm structure heightof the annular t 0.5 mm-5.0 mm  support structure

In embodiments, a self-supporting filter element (not illustrated) knownto those skilled in the art may be disposed in the container and eitherremovably or permanently joined to an interior surface of the container.For example, the filter may be in the shape of an inverted hollow conehaving a curved wall tapering evenly from a rim surrounding an opening.The filter element then may be placed in the container so that the apexof the cone is supported on and slightly flattened by the base of thecontainer, thereby enlarging the volume within the cone and providingbeneficial support for the filter element.

In embodiments, the container provided herein further comprises apierceable cover in a hermetically sealed relationship with the lip ofthe container, closing the opening to form a cartridge. The coverdesirably is formed of an impermeable and imperforate material that maybe pierced with an instrument, such as a tubular needle, through whichhot water is delivered for preparation of the beverage. For example, inembodiments the cover may comprise a polymer film or a foil heat-sealedto the lip of the container.

In embodiments, the containers may be prepared by molding andthermoforming the container from a thermoplastic material. Desirably,the thermoplastic material is substantially impermeable and imperforate.Non-limiting examples of suitable thermoplastic materials includepolyolefins such as polypropylene and polyethylene, polystyrene, nylon,and other polymers. In particular embodiments, it is particularlydesirable that the thermoplastic material be a bio-based resin, readilyrecycleable, and/or comprise at least a portion of recycled material.For example, in an embodiment the thermoplastic material may comprise arecycled polypropylene base resin.

In embodiments, the thermoplastic material may be blended with one ormore additives to impart the desired mechanical and thermal propertiesto the container. For example, in embodiments the thermoplastic materialmay be blended with one or more additives to impart the desiredstiffness to the container. In an embodiment, the additive comprises animmiscible polymer that may function as a stress concentrator byhindering the natural ability of the thermoplastic material to deformplastically and promoting controlled crack propagation. Non-limitingexamples of immiscible polymers that may be suitable for use with athermoplastic material comprising polypropylene include acrylics,styrenics, or their blends and copolymers with polyolefins. In anembodiment, the additive comprises a nucleating agent. In an embodiment,a second additive comprises a metallic stearate, non-limiting examplesof which include calcium stearate, magnesium stearate, zinc stearate,and combinations thereof. Other non-limiting examples of additivesinclude calcium carbonate, talc, clays, and nano grades of theseadditives.

In embodiments, the thermoplastic material comprises a blend of athermoplastic polymer, a nucleating agent, and a second additiveselected from the group consisting of calcium carbonate, talc, clay, andcombinations thereof. For example, the nucleating agent may be presentin the thermoplastic material in an amount from about 0.5 to about 5% byweight or about 0.5 to about 2.5% by weight, and the second additive maybe present in an amount from about 5 to about 25% by weight, about 5 toabout 20% by weight, about 7 to about 18% by weight, about 7 to about12% by weight, or about 9% by weight. For example, in embodiments thethermoplastic material may comprise a polypropylene, a nucleating agentin an amount from about 0.5 to about 2.5% by weight, and a secondadditive (e.g., talc) in an amount from about 7 to about 12% by weight.

In embodiments, the thermoplastic material comprises a monolayer or amultilayer material having at least two layers. Such materials are knownto those skilled in the art. For example, the thermoplastic material mayinclude a multilayered film having one or more layers formed of athermoplastic polymer and a barrier layer configured to improve thebarrier properties of the material. The multilayered film also mayinclude one or more tie layers disposed between the barrier layer andadjacent thermoplastic polymer layers and, optionally, one or morelayers of regrind. Non-limiting examples of barrier layers commonly usedin the art include ethylene vinyl alcohol (EVOH) and nylon, with theamount of the additive in the barrier layer being determined at least inpart by the particular application for which the container will be used.

For example, in an exemplary embodiment the thermoplastic material is amultilayered film having five (5) layers: thermoplastic polymer/tielayer/barrier layer/tie layer/thermoplastic polymer layer. For example,the thermoplastic polymer may be a polypropylene and the barrier layermay include EVOH. In another exemplary embodiment, the thermoplasticmaterial is a multilayered film having seven (7) layers: thermoplasticpolymer/regrind/tie layer/barrier layer/tie layer/regrind/thermoplasticpolymer.

Desirably, the containers provided herein have a puncture load of lessthan about 6 kg. As used herein, the “puncture load” means the forcerequired to puncture the continuous puncture region in the base of thecontainer using a needle. It should be appreciated that the punctureload depends in part on the type of needle used to measure the punctureload of a container. For example, the puncture load measured using adull needle generally will be greater than the puncture load measuredusing a sharp needle. For example, in embodiments the containers mayhave a puncture load measured using a sharp needle of less than about 3kg, less than about 2.75 kg, or less than about 2.5 kg. In embodiments,the containers may have a puncture load measured using a sharp needle ofabout 4.2 to about 3 kg, about 2.99 to about 2.75 kg, or about 2.74 toabout 2.5 kg. In embodiments, the containers may have a puncture loadmeasured using a dull needle of less than about 5 kg. For example, thecontainers may have a puncture load measured using a dull needle ofabout 4.0 to about 5.0 kg.

In embodiments, the container may be configured to receive an insert inwhich the dry beverage ingredients are disposed. For example, thecontainer may be configured to receive an insert comprising a filter cupin which are disposed the ingredients for preparing a beverage. Forexample, the container may further comprise a filter cup comprising abrew substance, non-limiting examples of which include coffee grinds,ground tea leaves, chocolate, flavored powders, and the like. The brewsubstance also may include a combination of dry milk, sugar or sugarsubstitute, or other flavorings to enhance the quality of the resultingbeverage.

The containers embodied herein are particularly suited for use in anautomatic machine, such as a coffee brewing machine. Upon placing thecontainer in the machine, a piercing member punctures the cover tointroduce pressurized hot water through the hole where it comes intocontact with the beverage ingredients disposed in the filter. A secondpiercing member punctures the base of the container at any position inthe continuous puncture region to enable the prepared beverage to flowout of the container and be dispensed into a cup or container forconsumption by the consumer.

The containers provided herein also may be configured for use with othertypes of food products, non-limiting examples of which include dryingredients for preparing broths, soups, and sauces that may be eaten bethemselves or used to prepare a food dish.

The foregoing embodiments can be further understood and illustrated bythe following non-limiting examples.

EXAMPLES Example 1

Containers (1.9 ounces) were prepared from multi-layer sheets usingvarious combinations of polypropylene compounds, different additives,and barrier materials. Polypropylene base resins included a highstiffness polypropylene and a homopolymer polypropylene and were usedeither alone or in combination with a stearate masterbatch (Stearate MB)and nucleating agent (NA).

The containers included both an annular support structure and an innersupport structure with a continuous puncture region therebetween, theannular support structure being in the form of a ring and the innersupport structure being in the form of a circle (i.e., the base of thecontainer had a “donut” shape with a “pineapple” design included on theinside of the container base). The containers were then tested forpunctureability with a dull needle (i.e., a needle that has a curvedpuncturing point rather than a pointed puncture point). When thepuncturing point is curved, the load distribution during puncturingchanges, resulting in a different behavior of the cups. The results formultilayer containers having seven (7) layers(Polypropylene/Regrind/Tie/Barrier/Tie/Regrind/Polypropylene) aresummarized in the following table, which lists the differentpolypropylene formulations used in the experiments. The barrier layerincluded 4% EVOH.

PP Compounds Puncture load, Kg High stiffness PP + 4.5% Stearate MB + 1%NA 5.04 High stiffness PP + 4.5% Stearate MB + 2% NA 4.74 HomopolymerPP + 4.5% Stearate MB + 1% NA 4.67 Homopolymer PP + 4.5% Stearate MB +2% NA 7.67

Example 2

Containers (1.9 ounces) were prepared from monolayer sheets usingvarious combinations of polypropylene compounds and different additives.Polypropylene base resins included a high stiffness polypropylene (PP B)and a homopolymer polypropylene (PP A) and were used alone or incombination with a nucleating agent (NA), calcium carbonate, or talc. Itshould be noted that both polypropylene resins were nucleated; however,the concentration of nucleating agents present in the base resin areproprietary. Generally, the concentration of nucleating agents in theseresins is about 0.1% (about 1000 ppm).

The containers included both an annular support structure and an innersupport structure with a continuous puncture region therebetween, theannular support structure being in the form of a ring and the innersupport structure being in the form of a circle. The containers werethen tested for punctureability with a dull needle (i.e., a needle thathas a curved puncturing point rather than a pointed puncture point) tomeasure the puncture load (kg) and displacement (mm). Additionally, thenon-puncture rate was determined from the percentage of containers thatdid not puncture during testing of ten (10) cups for each type ofthermoplastic material formulation.

Puncture Displace- Non- load* ment* puncture Thermoplastic Material ⁺(kg) (mm) Rate (%) 85% PP B + 15% Calcium Carbonate 4.76 7.66 50 85% PPA + 15% Calcium Carbonate 4.31 7.06 40 50% PP A + 50% PP B 4.28 6.66 2096% PP A + 4% PolyOne ® 4.37 6.93 20 98% PP A + 2% NA 4.06 6.65 10 94%PP A + 4% PolyOne ® + 4.69 6.66 10 2% NA 49% PP A + 49% PP B + 2% NA4.70 7.42 10 85% PP A + 15% Talc 4.69 6.70 0 ⁺ The concentrations arethe amount of additional additive added to the base resin and do notinclude any additives that may be present in the supplier's proprietaryblends. *The puncture load and displacement exclude values fromexperiments where the container was not punctured.

It should be apparent that the foregoing relates only to certainembodiments of the present application and the resultant patent.Numerous changes and modifications may be made herein by one of ordinaryskill in the art without departing from the general spirit and scope ofthe invention as defined by the following claims and the equivalentsthereof.

We claim:
 1. A container comprising: a substantially circular base; afrustoconically shaped wall extending from an edge of the base anddefining a cavity therein; and a stacking shoulder which intersects andextends laterally from the wall; wherein the base comprises an annularsupport structure having a continuous puncture region therein, theannular support structure being positioned an effective distance fromthe edge of the base to increase the punctureability of the base; andwherein the continuous puncture region is sized and shaped to permit apuncture therein without interference and without substantialdeformation of the container.
 2. The container of claim 1, wherein theeffective distance from the edge of the base to the annular supportstructure is from about 0.5 to about 10.0 mm.
 3. The container of claim1, wherein the annular support structure has a width from about 0.5 toabout 5 mm.
 4. The container of claim 1, wherein the container comprisesa thermoplastic polymer selected from the group consisting ofpolypropylene, polystyrene, nylon, polyethylene, and combinationsthereof.
 5. The container of claim 4, wherein the thermoplastic polymeris blended with one or more additives.
 6. The container of claim 5,wherein the one or more additives are selected from the group consistingof metallic stearates, calcium carbonate, talc, clays, and combinationsthereof.
 7. The container of claim 6, wherein the one or more additivescomprise metallic stearates selected from the group consisting ofcalcium stearate, magnesium stearate, zinc stearate, and combinationsthereof.
 8. The container of claim 1, wherein the container comprises athermoplastic material including a thermoplastic polymer, a nucleatingagent in an amount from about 0.5 to about 5.0% by weight of thethermoplastic material, and talc in an amount from about 7.0 to about18.0% by weight of the thermoplastic material.
 9. The container of claim1, wherein the container comprises a thermoplastic material including apolyolefin, a nucleating agent in an amount from about 0.5 to about 2.5%by weight of the thermoplastic material, and talc in an amount fromabout 7.0 to about 12.0% by weight of the thermoplastic material. 10.The container of claim 1, wherein the container has improvedpunctureability as characterized by a puncture load of less than 6.0 kg.11. The container of claim 1, wherein the container has improvedpunctureability as characterized by a puncture load of about 2.5 kg toabout 5.0 kg.
 12. The container of claim 1, further comprising a featureimprinted on an inner surface of the base, wherein the feature functionsto increase the punctureability of the base.
 13. The container of claim1, wherein the container is recycleable.
 14. A thermoplastic materialcharacterized by improved punctureability comprising a polyolefin, anucleating agent in an amount from about 0.5 to about 5.0% by weight ofthe thermoplastic material, and talc in an amount from about 5.0 toabout 25.0% by weight of the thermoplastic material.
 15. Thethermoplastic material of claim 14, wherein the nucleating agent ispresent in an amount from about 0.5 to about 2.5% by weight of thethermoplastic material and the talc is present in an amount from about7.0 to about 18.0% by weight of the thermoplastic material.
 16. Thethermoplastic material of claim 14, wherein the improved punctureabilityis characterized by a puncture load of less than 6.0 kg.
 17. Thethermoplastic material of claim 14, wherein the improved punctureabilityis characterized by a puncture load of about 2.5 kg to about 5.0 kg. 18.The thermoplastic material of claim 14, wherein the polyolefin comprisesa polypropylene resin or a polyethylene resin.
 19. A container forforming a beverage comprising the container of claim 1, and furthercomprising: a filter disposed in the cavity of the container anddefining first and second chambers in the cavity; a beverage mediumdisposed in the cavity and arranged to interact with a liquid introducedinto the container to form a beverage; and a lid attached to a rim ofthe container to contain the beverage medium and filter disposedtherein.
 20. A container for forming a beverage formed from athermoplastic material comprising a polyolefin, a nucleating agent in anamount from about 0.5 to about 5.0% by weight of the thermoplasticmaterial, and talc in an amount from about 5.0 to about 25.0% by weightof the thermoplastic material.